Equipment for nuclear power plant units

Project to manufacture and deliver equipment for 2 power plant units with VVER-1200 reactor systems

A contract for the manufacture and delivery of reactor equipment for Novovoronezh NPP-2 was signed in 2007 by and between Open Joint-Stock Company Izhorskiye Zavody and the state-owned corporation Rosatom. This contract provides for the production of two sets of primary equipment for a VVER-1200 reactor system, specifically reactor vessels with internals and upper blocks, steam generator vessels, pressure compensators, main circulation pumps (MCP) and other equipment, all having a total mass of over 3,500 tons.

As part of this contract, in 2011 Izhorskiye Zavody delivered essential equipment to Novovoronezh NPP-2 (Unit 1) a VVER-1200 reactor vessel. This was the first nuclear reactor vessel manufactured in Russia for a Russian nuclear power plant (NPP) in the last 20 years.

Before the reactor vessel was shipped, it underwent hydraulic pressure testing in accordance with the Hydraulic Testing Program and Methodology, which involves creating a maximum pressure of 24.5 MPa within the reactor vessel and conducting a test assembly of the vessel with internals and the upper block. Test results were assessed by a commission that included representatives from the Open Joint-Stock Companies Rosenergoatom Concern (affiliate of Novovoronezh NPP-2), Atomenergoproekt, Direktsiya Edinovo Zakazchika (Integrated Customer Directorate), CKBM, FGUP VO Safety, and the Experimental Design Bureau (OKB) Gidropress. The tests confirmed that the manufactured equipment conforms to the requirements of detailed design documentation and to the requirements of the Rules and Standards for the Nuclear Power Industry.

Shipment of the VVER-1200 reactor vessel for the Novovoronezh NPP-2, considering the vessel's weight and dimensions (weight of over 300 tons, diameter of approximately 4.5 meters, and length of 11 meters), was a truly unique transport operation with multiple railway crossings on the Oktyabrskaya Railway. The VVER-1200 reactor vessel was shipped to the customer by waterway from the Izhorskiye Zavody loading dock on the Neva River in the village of Ust-Slavyanka.

Reactor vessel equipment for Novovoronezh NPP-2 (Unit 2) is currently in various stages of completion at production shops of Izhorskiye Zavody. This equipment includes the reactor vessel with internals, the upper block, and a pressure compensator.

The manufacture of nuclear power plant equipment at Izhorskiye Zavody is licensed by Russia's Federal Service for Environmental, Technological and Nuclear Oversight, the Chief Directorate of Oversight for Quality, Inspection, and Quarantine of the People's Republic of China, and others. All projects and plans for manufacturing nuclear power equipment comply with IAEA requirements for reliability and safety.

The Customer

The state-owned nuclear power corporation Rosatom, which combines over 240 enterprises and scientific organizations, is the largest power-generating company in Russia and provides more than 40% of the electrical power in the European portion of Russia. Rosatom maintains a leading position on the global nuclear technologies market, occupying the world's top position for quantity of nuclear power plants being simultaneously built abroad, 2nd in global uranium reserves and 5th in uranium production volume, and 4th place in nuclear-generated electricity, while also supplying 40% of the global market for uranium enrichment services and 17% of the nuclear fuel market.

This state-owned corporation Rosatom ensures implementation of government policy and integrated management of nuclear power usage, stable operation of nuclear-generated electric power and nuclear weapon complexes, and nuclear and radiation safety. The state-owned corporation Rosatom was established to promote fulfillment of the federal target program for development of the nuclear industry, to provide for new conditions for the development of nuclear power, and to strengthen Russia's existing competitive advantages on the global nuclear technologies market.

Nuclear power plants are designed by three engineering companies that were created in 2007 based on three design institutes called Atomenergoproekt in Moscow, St. Petersburg, and Nizhny Novgorod. All Atomenergoproekt institutes are general designers of nuclear power plants and perform the full range of design and survey work for building and upgrading nuclear power plants, including operations for selecting sites for construction, development of preliminary design and detailed design documentation, designer supervision of nuclear power plant construction, technical support of their operation, as well as organization of construction and assembly works, delivery of equipment and materials, and start-up and commissioning of nuclear power plants. In other words, they are capable of building turn-key nuclear power plants.

Rosatom is implementing projects to build nuclear power plants both in Russia (Baltic NPP, Beloyarsk NPP-2, Leningrad NPP-2, Nizhegorod NPP, Novovoronezh NPP-2, Rostov NPP, Central NPP) and abroad (Akkuyu NPP (Turkey), Belarusian NPP, Bushehr NPP (Iran), Kudankulam NPP (India), Mochovce NPP (Slovakia), Tianwan NPP-2 (China), and Khmelnitskiy NPP).

Novovoronezh NPP-2 is a next-generation nuclear plant that is being built according to Atomenergoproekt's NPP-2006 project employing the VVER-1200 reactor system. This is an evolutionary development of the NPP-92 VVER-1000 project.

The Novovoronezh NPP-2 project was developed for two power units with the possibility of expansion to four. This project is for a universal nuclear power plant that provides the capability to build reference nuclear plants in regions with various natural and geographic conditions and various man-made impacts. The design service life of the structures is 100 years.

The Novovoronezh NPP-2 project employs an evolutionary generation III+ reactor system for which:

  • The service life of the primary equipment has been extended to 60 years
  • Downtime duration has been reduced and the installed capacity utilization factor has been increased
  • The safety systems include the following new passive technologies: passive heat removal system, passive reactor core flooding, passive annulus filtration system, passive containment and retention of molten reactor core material (corium).

Izhorskiye Zavody is the only reference producer of completely packaged «Nuclear Island» equipment for NPP with water-cooled power reactors (known as VVER) with capacities of 1,000 and 1,200 MW (VVER-1000 and VVER-1200).

Technical capabilities

Over the entire history of nuclear power development, Izhorskiye Zavody has manufactured approximately 60 sets of equipment for NPP employing VVER-440 and VVER-1000 reactors in Russia, Ukraine, Bulgaria, Slovakia, Finland, India, China, and Iran.

The cumulative operating time of VVER-440 reactors is about 400 reactor-years, and more than 200 reactor-years for VVER-1000 reactors.

The successful half-century operational history of water-cooled nuclear reactors produced by Izhorskiye Zavody at NPP in various countries serves as confirmation of their reliability and safety. All stages of the equipment life cycle are provided with qualified designer supervision over the construction of power units and technical support of their operation.

Izhorskiye Zavody employs the ISO 9001:2008 quality management system certified by Bureau Veritas and GosStandard of Russia.